【発明の詳細な説明】 本発明は、成形工程で補助プラグおよび真空吸
引を利用する熱成形法によつてポリスチレン等の
熱可塑性発泡材を成形する方法に関する。DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of molding thermoplastic foams such as polystyrene by thermoforming processes that utilize auxiliary plugs and vacuum suction during the molding process.
従来、周知の熱可塑性樹脂押出法を利用して最
初にシート状に成形した熱可塑性シート材から成
品を加工するためには、マツチドモールド熱成形
が広く採用されてきた。まず、シート材は予熱し
てから雄型と雌型との間に置かれ、次いでそれら
を閉じることによつててこのシート材が所望形状
にプレスされ成形されるのである。このような成
形法では、成形された製品における材料分布は金
型部分の形状によつてきまる。 Conventionally, matt mold thermoforming has been widely employed to process products from thermoplastic sheet materials that are first formed into sheets using well-known thermoplastic resin extrusion methods. First, the sheet material is preheated and placed between a male mold and a female mold, and then the sheet material is pressed and formed into the desired shape by closing them. In such molding methods, the material distribution in the molded product depends on the shape of the mold parts.
可塑性シートを熱成形するために採用し得る別
の成形法は真空熱成形である。予熱したシートの
真下側を真空にすることによつて、シートの上側
にかかる大気圧の作用でシートを押し付けて金型
に接触させるのである。シートが金型に接触する
と、冷却されて所望の形状に硬化する。シート材
の各部分のうち真空金型部材に最後に接触する部
分は、通常、成形される材料の他の部分よりもよ
り大きく引張られているため、最も薄くなる。 Another forming method that may be employed to thermoform plastic sheets is vacuum thermoforming. By creating a vacuum just below the preheated sheet, the atmospheric pressure applied to the upper side of the sheet forces the sheet into contact with the mold. When the sheet contacts the mold, it is cooled and hardened into the desired shape. The portions of the sheet material that are the last to contact the vacuum mold member are typically the thinnest because they are under greater tension than other portions of the material being formed.
その他の公知の熱成形法としては二段熱成形法
があり、それによれば予熱した可塑性シートをそ
の一部だけを所望形状に予備成形し、次いでこの
予備成形工程を経てから熱成形工程を行ない、成
形を完了する。この方法ではマツチドモールド部
材を使い、それらが共働して目的とする最終成品
に成形するのである。米国特許第3825166号はそ
のような成形法を開示している。 Another known thermoforming method is a two-stage thermoforming method, in which only a portion of a preheated plastic sheet is preformed into the desired shape, and then this preforming step is followed by a thermoforming step. , complete the molding. This method uses mated mold parts that work together to form the desired final product. US Pat. No. 3,825,166 discloses such a molding method.
本発明は：(i) 厚さ１ないし５mmの熱可塑性樹脂発泡材のシ
ートを118ないし140℃の温度に予熱する工程；(ii) 予熱した前記発泡材を一定の位置に締付け、
固定する工程；(iii) ダイ部材を成形キヤビテイ内に移動させるこ
とによつて、予熱発泡材を成形キヤビテイに向
かつて部分的に変形する工程；(iv) 前記発泡材を十分には冷却することなく部分
的に変形した状態で0.1〜2.0秒の間この発泡材
を保持する工程；および(v) 部分的に変形された予熱シートを真空吸引に
より前記成形キヤビテイ内に押込むことによつ
て成品にまで完全に成形する工程；の各連続する工程から成る、熱可塑性樹脂成品の
製造方法を提供する。 The present invention comprises: (i) preheating a sheet of thermoplastic foam having a thickness of 1 to 5 mm to a temperature of 118 to 140°C; (ii) tightening the preheated foam in a fixed position;
(iii) partially deforming the preheated foam toward the molding cavity by moving a die member into the molding cavity; (iv) sufficiently cooling said foam; (v) holding the foam in a partially deformed state for a period of 0.1 to 2.0 seconds; and (v) forming a product by forcing the partially deformed preheated sheet into the molding cavity by vacuum suction. Provided is a method for producing a thermoplastic resin article, which comprises the following steps: completely molding the article.
本発明によれば、ポリスチレン発泡体のような
熱可塑性樹脂発泡成品は、熱可塑性樹脂発泡シー
トを所望温度に予熱し、特別に設定したプラグ部
材を使つて予め張力をかけて型の雌型内で発泡材
を予備成形する。プラグ部材が完全に押出された
位置に来たときに、熱成形工程の完結に先立つて
0.1ないし2.0秒、好ましくは0.6ないし1.2秒の程
度の短かい遅れ時間が経過し得るようになつてい
る。熱成形は真空吸引およびそれに続いてマツチ
ドモールド部材を完全に閉じることによつて完結
する。目的成品の成形に続いて金型部分を分割
し、熱可塑性シートを適宜位置に押し出して、成
形サイクルを繰り返えすに先立つて成形発泡成品
を上記シートから耳切り（トリム）してもよい。 According to the present invention, a thermoplastic foamed product such as polystyrene foam is produced by preheating a thermoplastic foam sheet to a desired temperature and pre-tensioning it into the female mold using a specially designed plug member. Preform the foam material. When the plug member is in the fully extruded position, the
It is provided that short delay times of the order of 0.1 to 2.0 seconds, preferably 0.6 to 1.2 seconds, can elapse. Thermoforming is completed by vacuum suction followed by complete closure of the mated mold members. Following molding of the desired product, the mold sections may be split, the thermoplastic sheet extruded into position, and the molded foam article trimmed from the sheet prior to repeating the molding cycle.
本発明は、カツプのような熱成形発泡成品を製
造する方法を提供するものであつて、得られる成
品は深さ対頂部直径の比の範囲がこれまでのもの
と比較してより大きくとることができる。さら
に、本発明の方法によれば、成形された成品自体
も、成品に高い強度を与えるに十分な材料分布を
側壁部および底部に沿つて有しているため、広範
囲の用途に利用可能となる。 The present invention provides a method for manufacturing thermoformed foam articles, such as cups, in which the resulting articles have a greater range of depth to top diameter ratios than previously known products. Can be done. Furthermore, according to the method of the present invention, the molded product itself has sufficient material distribution along the side walls and bottom to provide high strength to the product, making it usable for a wide range of applications. .
一般に、熱可塑性樹脂、例えばポリスチレンの
予め成形された発泡シート材料は厚さが１〜５
mm、好ましくは2.3〜３mmであつて、これは所要
成形温度に予熱される。この所要成形温度は成形
する熱可塑性樹脂の組成および特性に応じて大き
く変わる。しかし、ポリスチレンの場合、発泡材
成形温度は118℃〜140℃、好ましくは124℃〜135
℃である。この予熱発泡シートは熱成形金型の金
型部分の間に供給され、そこでマツチドモール
ド、補助プラグおよび真空成形を組合せて利用す
ることにより所望成品に成形される。すなわち、
まず上記発泡シートを所定位置に最初しつかりと
固定し、拘束してから、プラグ部材を押し出すこ
とによつて、金型キヤビテイがその周りにおいい
かぶさるにつれて、シートに張力をかける。成形
キヤビテイが完全に閉じられたときに、キヤビテ
イ側（すなわち、雌型部材側）から真空吸引し、
成品の成形を続ける。対応するコア部材（すなわ
ち、雄型部材）を次いでキヤビテイ内に押し込ん
で、成品を冷却して硬化させるとともに最終成品
の厚さを制御する。 Generally, preformed foam sheet materials of thermoplastics, such as polystyrene, have a thickness of 1 to 5 mm.
mm, preferably 2.3 to 3 mm, which is preheated to the required forming temperature. The required molding temperature varies greatly depending on the composition and properties of the thermoplastic resin to be molded. However, for polystyrene, the foam molding temperature is 118℃~140℃, preferably 124℃~135℃
It is ℃. The preheated foam sheet is fed between the mold sections of a thermoforming mold where it is formed into the desired product using a combination of mated molding, auxiliary plugs and vacuum forming. That is,
The foam sheet is first held firmly in place, restrained, and then the sheet is tensioned as the mold cavity is wrapped around it by pushing out the plug member. When the molding cavity is completely closed, apply vacuum from the cavity side (i.e., female mold member side),
Continue molding the finished product. A corresponding core member (ie, male member) is then forced into the cavity to cool and harden the article and to control the thickness of the final article.
得られる成品の特性は、発泡シートの密度、セ
ル寸法、厚さ、スキン層の厚さ、成形時の材料の
温度、補助プラグ成形工程で使用するプラグの形
状、プラグを構成する材料、および成形サイクル
の各工程の所要時間等の多くの要因によつて決定
される。 The properties of the resulting product are determined by the density of the foam sheet, cell dimensions, thickness, skin layer thickness, temperature of the material during molding, shape of the plug used in the auxiliary plug molding process, material constituting the plug, and molding. It is determined by many factors, such as the time required for each step of the cycle.
本発明のその他の特徴および利益は添付図面に
関連させた好適具体化例についての以下の説明か
ら明らかとなろう。 Other features and advantages of the invention will become apparent from the following description of a preferred embodiment, taken in conjunction with the accompanying drawings.
図示例にあつては、ポリスチレン発泡シートは
直接射出押出法によつて製造された。このシート
の密度は約176Kg／m2、厚さは約2.5mmであつた。
このポリスチレン発泡シートの外側スキン層は厚
さが約76ミクロンであつた。第１図に示すよう
に、ポリスチレン発泡シートは最初予熱帯域１を
通過し、そこで輻射加熱器を使つてシートの温度
を、例えば約130℃という、容易に目的成品に成
形できる温度にまで高める。予熱されたポリスチ
レン発泡シート２は次いで成形帯域に送られ、そ
こで対になつた環状部材３によつて、シートは一
定の位置に固定される。これらの環状部材３は予
熱シートの上方および下方に設けられていて成形
ステーシヨンを完全に取り込んでいる。この関係
は第２図により明確に示されており、固定用の環
状部材３は発泡シートを固定するとともに成形に
先立つて発泡シートをその位置に拘束する。第３
図に示すように、プラグ部材４は、雄型部材４′
から伸びていて、発泡シート２を一部キヤビテイ
５′内にまで押出して張力を与えるために使用さ
れている。 In the illustrated example, the polystyrene foam sheet was manufactured by direct injection extrusion. The density of this sheet was approximately 176 Kg/m2 and the thickness was approximately 2.5 mm.
The outer skin layer of the polystyrene foam sheet was approximately 76 microns thick. As shown in Figure 1, the polystyrene foam sheet first passes through a preheating zone 1, where a radiant heater is used to increase the temperature of the sheet to, for example, about 130 DEG C., a temperature at which it can be easily formed into desired products. The preheated polystyrene foam sheet 2 is then fed to a forming zone where it is fixed in position by a pair of annular members 3. These annular members 3 are arranged above and below the preheating sheet and completely enclose the forming station. This relationship is clearly shown in FIG. 2, where the securing annular member 3 secures the foam sheet and restrains it in position prior to molding. Third
As shown in the figure, the plug member 4 includes a male member 4'
It is used to partially extrude the foam sheet 2 into the cavity 5' and apply tension.
金型部材の作特機構は、図示していないが、一
般の従来装置によるものである。型部材４，５は
液圧で作動する定盤上にそれぞれ取り付けられて
いる。発泡シート２を加熱して成形帯域に送つて
から、雌型部材５が取り付けられている定盤の型
締を開始する。この定盤の型締が進むにつれ、多
くのリミツトスイツチが作動し、最初のリミツト
スイツチが固定要素である環状部材３を駆動さ
せ、そして第二のリミツトスイツチがプラグ部材
４を駆動させる。このプラグ部材４は減圧によつ
て作動する。上記定盤が完全に閉じたときに、雄
型部材４′が取り付けられている下側の定盤が型
締を開始する。この定盤の型締が進むにつれ、真
空を制御する第三のリミツトスイツチを作動させ
る。したがつて、金型が完全に閉じられるに先立
つて、定盤の型締につれて真空装置が作動して真
空吸引を開始する。成品への成型は、したがつ
て、この真空吸引によつて行なわれる。金型の全
体の型締は成品の厚さ制御および冷却のためだけ
に行なわれる。プラグ部材４が発泡シート２を成
形キヤビテイ５′内に押込んで予め張力を与える
につれて、同時に雌型部材５も雄型部材４′に向
かつて閉じられる（第４図参照）。プラグ部材４
が完全に押出されたときに、約0.9秒程度の遅れ
で、成形キヤビテイ５′内の真空吸引が開始する。
この停止時間、つまり遅れ時間が余りに短かすぎ
ると、すなわち約0.1秒以下であると、成品の底
部および下方の側壁の成品厚さが許容できない程
に薄くなつてしまうことが分かつた。一方、この
停止時間が長すぎると、シートが過度に冷却さ
れ、真空で吸引したときに割れてしまう。 The mold member forming mechanism is not shown, but is based on a general conventional device. The mold members 4, 5 are each mounted on a hydraulically operated surface plate. After the foamed sheet 2 is heated and sent to the molding zone, mold clamping of the surface plate to which the female mold member 5 is attached is started. As the mold clamping of the surface plate progresses, many limit switches are activated, the first limit switch driving the annular member 3 which is a fixing element, and the second limit switch driving the plug member 4. This plug member 4 is actuated by reduced pressure. When the surface plate is completely closed, the lower surface plate to which the male mold member 4' is attached starts clamping. As the surface plate is clamped, a third limit switch is activated to control the vacuum. Therefore, before the mold is completely closed, the vacuum device is activated to start vacuum suction as the surface plate is clamped. Molding into a finished product is therefore carried out by this vacuum suction. The entire mold is clamped only for thickness control and cooling of the finished product. As the plug member 4 forces the foam sheet 2 into the mold cavity 5' and pretensions it, the female member 5 is simultaneously closed towards the male member 4' (see FIG. 4). Plug member 4
When the molding cavity 5' is completely extruded, vacuum suction inside the molding cavity 5' starts with a delay of about 0.9 seconds.
It has been found that if this dwell or delay time is too short, less than about 0.1 seconds, the product thickness at the bottom and lower sidewalls of the product becomes unacceptably thin. On the other hand, if this stopping time is too long, the sheet will cool down too much and will crack when vacuumed.
第５図に一層明確に示してあるように、制御さ
れた真空は、慣用の手段（図示せず）によつて導
路６を介して適用される。真空は約0.6秒間成形
キヤビテイ５′内においてシートに適用される。
これによりシートはプラグ部材４から離れて成形
キヤビテイ５′内に吸引され、同時にこのとき雄
型部材４′が成形キヤビテイ５′内への型締を行な
い、またプラグ部材４は雄型部材４′内に引込め
られる。第６図に示すように、このとき雄型部材
４′は成形キヤビテイ５′内に完全に閉じられ、成
品の厚さを、例えば、金型部材が型締位置にある
ときに両金型部材の間にみられらる予め定めた一
定の隙間（ギヤツプ）に応じて、制御する。コア
部材すなわち雄型部材４′はこの成形された成品
をさらに冷却し、金型部材を開いたときに成品に
そりが生じないようにする。約1.8秒の十分な停
止時間の経過後、金型部材を第７図に示すように
開き、導路８から空気ブラストを送つて雌型の成
形キヤビテイ５′からの成形カツプの突出を助け
る。さらに、成形キヤビテイ５′の頂部に設けら
れている突出ピストン９を駆動させ、型抜きを行
なつて成形成品を成形キヤビテイ５′から押出す。
金型部材は、最終的には、第１図に示すように完
全に開かれ、シートは前進し、また成形サイクル
が繰り返えされる。前進するシートは最后にトリ
ムステーシヨンにまで送られ、最終成品がシート
からトリムつまり切断される。 As shown more clearly in FIG. 5, a controlled vacuum is applied via conduit 6 by conventional means (not shown). Vacuum is applied to the sheet within mold cavity 5' for approximately 0.6 seconds.
As a result, the sheet is separated from the plug member 4 and sucked into the molding cavity 5', and at the same time, the male member 4' clamps the mold into the molding cavity 5', and the plug member 4 is pulled into the molding cavity 5'. be pulled inside. As shown in FIG. 6, the male mold member 4' is then completely closed within the molding cavity 5', and the thickness of the product can be determined, for example, by both mold members when the mold members are in the clamping position. Control is performed according to a predetermined gap between the two. The core or male mold member 4' further cools the molded article and prevents it from warping when the mold members are opened. After a sufficient dwell time of approximately 1.8 seconds, the mold members are opened as shown in FIG. 7 and an air blast is directed from channel 8 to assist in ejecting the mold cup from the female mold cavity 5'. Further, the projecting piston 9 provided at the top of the molding cavity 5' is driven to perform die cutting and extrude the molded product from the molding cavity 5'.
The mold members are eventually fully opened as shown in FIG. 1, the sheet is advanced, and the molding cycle is repeated. The advancing sheet is ultimately fed to a trim station where the final product is trimmed or cut from the sheet.
成形操作の間、金型部材、すなわちプラグ部材
４、雄型部材４′および雌型部材５の温度は一般
に10℃ないし約120℃の範囲内に制御される。プ
ラグ部材４および雄型部材４′は好ましくは約80
〜100℃の温度に保持される。雌型部材５は好ま
しくは約65〜93℃の温度に保持される。以上述べ
た例では、それぞれ約93℃および約80℃に保持し
た。予熱炉温度は約230〜300℃の範囲にあつた。 During the molding operation, the temperature of the mold members, namely plug member 4, male member 4' and female member 5, is generally controlled within the range of 10°C to about 120°C. Plug member 4 and male member 4' preferably have a diameter of about 80
Maintained at a temperature of ~100°C. The female mold member 5 is preferably maintained at a temperature of about 65-93°C. In the examples described above, the temperatures were maintained at about 93°C and about 80°C, respectively. The preheating furnace temperature was in the range of approximately 230-300°C.
プラグ部材４の形成およびその材質は成形され
る成品の側壁に沿つた発泡シート材の材料分布を
直接制御する。構成材料の種類によつても材料分
布は大きく異なつてくる。したがつて、プラグ部
材の構成材料は、成形される成品の形状および成
形成品の所望材料分布に応じて各別に選ばなけれ
ばならない。適当な材料は、例えば、鋼、ナイロ
ン、アルミニウムおよび複合発泡材（シンタクチ
ツクフオーム）等である。代表的には、プラグ部
材の望ましい材料は、良好な絶縁材であつて、成
形期間中に加熱したりあるいは冷却したりしない
材料である。 The formation of plug member 4 and its material directly control the material distribution of the foam sheet material along the sidewalls of the article being molded. The material distribution also varies greatly depending on the type of constituent material. Therefore, the material of the plug member must be selected depending on the shape of the product to be molded and the desired material distribution of the product. Suitable materials include, for example, steel, nylon, aluminum and composite foam. Typically, desirable materials for the plug member are materials that are good insulators and do not heat or cool during molding.
以上の例では深さ対頂部直径の比が約1.25：
１、壁厚が約1.27mmであるカツプを成形したが、
その場合、形状がカツプの底部の形状と一致する
ものであつて、長さ約６mm鋼製プラグ部材によつ
てすぐれた結果が得られた。 In the example above, the depth to top diameter ratio is approximately 1.25:
1. I molded a cup with a wall thickness of about 1.27 mm.
In that case, excellent results were obtained with a steel plug member whose shape matched that of the bottom of the cup and which was about 6 mm long.
以上の例で製造された熱成形カツプは以下のよ
うな寸法であつた。 The thermoformed cups produced in the above examples had the following dimensions:
高 さ 89mm 頂部直径外 径 84mm 内 径 76mm 底部直径外 径 50.93mm 内 径 48.77mm 側壁角度 9゜ 密 度 72〜80Kg／m3 本例の場合、カツプの密度は72〜80Kg／m3であ
るが、従来の成形法ではそのように小さな密度の
ものは得られなかつた。従来のカツプ熱成形法で
は約160Kg／m3あるいはそれ以上の密度が一般的
である。Height 89mm Top diameter Outer diameter 84mm Inner diameter 76mm Bottom diameter Outer diameter 50.93mm Inner diameter 48.77mm Side wall angle 9° Density 72-80Kg/m3 In the case of this example, the density of the cup is 72-80Kg/m3 However, it has not been possible to obtain such a small density using conventional molding methods. Densities of about 160 Kg/m3 or higher are common in conventional cup thermoforming processes.
なお、本発明による方法は単一のあるいは複数
のキヤビテイをもつた金型を使つても実施しう
る。 It should be noted that the method according to the present invention can also be carried out using a mold having a single cavity or multiple cavities.
第１図は、予熱帯域から成形金型に送られると
きの熱可塑性樹脂発泡材のシートを示す、本発明
の方法に用いる装置の略式断面図；第２図ないし
第７図は、ポリスチレンカツプを成形するのに使
用される成形装置の成形順序を示す略式断面図；
および第８図は、成品の成形を終えたときの一部
開いた金型部分を示す略式断面図である。 １：予熱帯域、２：シート、３：環状部材、
４：プラグ部材、４′：雄型部材、５：雌型部材、
５′：成形キヤビテイ。 FIG. 1 is a schematic cross-sectional view of the apparatus used in the method of the invention showing the sheet of thermoplastic foam as it is fed from the preheating zone to the mold; FIGS. 2 to 7 show a polystyrene cup. A schematic cross-sectional view showing the molding sequence of the molding device used for molding;
and FIG. 8 is a schematic cross-sectional view showing a partially opened mold part when molding of a finished product is completed. 1: preheating zone, 2: sheet, 3: annular member,
4: Plug member, 4': Male member, 5: Female member,
5': Molding cavity.
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|---|---|---|---|
| US05/942,836US4239727A (en) | 1978-09-15 | 1978-09-15 | Method and apparatus for thermoforming thermoplastic foam articles |
| Publication Number | Publication Date |
|---|---|
| JPS5559920A JPS5559920A (en) | 1980-05-06 |
| JPS6332610B2true JPS6332610B2 (en) | 1988-06-30 |
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP11866279AGrantedJPS5559920A (en) | 1978-09-15 | 1979-09-14 | Manufacture of thermal plastic resin product and its device |
| Country | Link |
|---|---|
| US (2) | US4239727A (en) |
| EP (1) | EP0010847B1 (en) |
| JP (1) | JPS5559920A (en) |
| AU (1) | AU524203B2 (en) |
| CA (1) | CA1140715A (en) |
| DE (1) | DE2965668D1 (en) |
| ES (1) | ES484170A1 (en) |
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